Isuzu Cars and Trucks 1981-1991

Halfshafts (Driveshaft)

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REMOVAL AND INSTALLATION
Except All Wheel Drive Impulse
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the ball joint-to-lower control arm, strut rod and stabilizer bar bolts or nuts.
  4.  
  5. Remove the driveshaft nut and washer. Dislodge the shaft from the spindle splines with a plastic hammer.
  6.  
  7. Support the driveshaft to the strut with a piece of wire to prevent the shaft from falling.
  8.  



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Fig. FWD driveshaft assemblies



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Fig. Driveshaft nut installation

  1. Place a drain pan under the driveshaft. Using a suitable prybar, remove the driveshaft from the transaxle. The inner joint is retained by a circlip inside the differential housing. Be careful not to damage the inner joint by pulling the shaft apart.
  2.  

To install:

  1. Install the driveshaft into the transaxle. Push the shaft in until the circlip engages the differential groove.
  2.  
  3. Insert the driveshaft into the splined hole in the spindle.
  4.  
  5. Install the driveshaft nut and washer. Torque the nut to 100 ft. lbs. (136 Nm).
  6.  
  7. Install the ball joint-to-lower control arm, strut rod and stabilizer bar bolts.
  8.  
  9. Refill the transaxle with the proper amount of fluid. Connect the negative battery cable and check operation.
  10.  

FWD Impulse and Stylus
  1. Disconnect the negative battery cable.
  2.  
  3. Raise the vehicle and support with jackstands.
  4.  
  5. Drain the oil from the transaxle and transfer case (4WD only).
  6.  
  7. Pry the hub nut open and loosen the nut. The brake may have to applied when loosening.
  8.  
  9. Using a tie rod removing tool J2168702 or equivalent, disconnect the tie rod from the knuckle.
  10.  
  11. Remove the lower ball joint bolts and swing out of the way.
  12.  
  13. Pull the hub and knuckle away from the driveshaft. Be careful not to allow the shaft to fully extend. Damage to the inner joint may result.
  14.  
  15. Use a prybar to dislodge the inner joint from the differential. The shaft is held in by a circlip at the end of the splined shaft.
  16.  



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Fig. Driveshaft nut installation

To install:

  1. Install the inner joint into the differential and engage the circlip.
  2.  
  3. Insert the outer joint into the splined hub. Be careful not to allow the shaft to fully extend. Damage to the inner joint may result.
  4.  
  5. Install the lower ball joint bolts and tighten.
  6.  
  7. Install the hub nut and tighten. The brake may have to applied when tighten.
  8.  
  9. Refill the transaxle and transfer case (4WD only) with the specified oil.
  10.  
  11. Lower the vehicle.
  12.  
  13. Connect the negative battery cable.
  14.  

CV-JOINT OVERHAUL
Double Offset Joint
DISASSEMBLY
  1. Disconnect the negative battery cable. Clean the assembly of all grease and dirt.
  2.  
  3. Remove the inner joint boot clamps. Slide the boot off of the joint.
  4.  
  5. From inside the inner joint, remove the circular clip from inside the offset joint. Pull the joint and shaft off of the inner joint.
  6.  
  7. Remove the ball retainer snapring and ball retainer. Pull the ball retainer and ball book from the splined shaft.
  8.  
  9. Remove the boots and vibration damper, if so equipped.
  10.  

The outer (Birfield) joint is not serviceable, it must be replaced as an assembly.

  1. Clean all grease and dirt from the joints.
  2.  



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Fig. Remove the snapring and ball retainer

ASSEMBLY
  1. With the Birfield joint bent at a 40and#x00B0; angle, turn the shaft and make sure that it turns smoothly and normally.
  2.  
  3. Place tap on the splines to prevent damage to the joint boots.
  4.  
  5. Install the outer boot and clamps onto the outer shaft.
  6.  
  7. Fill the joint and boot with new CV-joint grease and install new clamps.
  8.  
  9. Install the inner joint boot and vibration damper, if so equipped.
  10.  
  11. Install the ball retainer, guide and snapring.
  12.  
  13. Fill the boot and off-set joint with new grease and install joint.
  14.  
  15. Install the circular clip into the groove.
  16.  
  17. Slide the boot onto the joint, insert a tool under the boot lip to allow the pressure to equalize and tighten the new clamps.
  18.  
  19. Install the shaft into the vehicle as outlined in this Section.
  20.  



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Fig. Assembly of Double Offset CV-Joint

Tripod Joint
DISASSEMBLY
  1. Remove the driveshaft from the vehicle as outlined in this Section.
  2.  
  3. Remove the boot clamps and inner joint housing. Mark off an alignment mark on both the housing and shaft. Use paint or a marker instead of a punch.
  4.  
  5. Remove the snapring from the shaft.
  6.  
  7. Using a punch, mark the shaft and tripod assembly for assembly. Using a wooden driver, remove the tripod from the splined shaft. Remove the boot from the shaft.
  8.  



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Fig. Disassembly of Tripod CV-joint

ASSEMBLY
  1. Place tape over the splines to protect the boot during installation.
  2.  
  3. Install the boot and insert the tripod onto the shaft with the shorter spline positioned on the outer side. Drive the tripod onto the shaft with a wooden driver and install the snapring.
  4.  
  5. Apply new CV-joint grease to the housing and boot.
  6.  
  7. Install the housing onto the tripod at the alignment marks and install new boot clamps.
  8.  

 
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